Coke ovens having monolith component construction

ABSTRACT

The present technology is generally directed to horizontal heat recovery and non-heat recovery coke ovens having monolith components. In some embodiments, an HHR coke oven includes a monolith component that spans the width of the oven between opposing oven sidewalls. The monolith expands upon heating and contracts upon cooling as a single structure. In further embodiments, the monolith component comprises a thermally-volume-stable material. The monolith component may be a crown, a wall, a floor, a sole flue or combination of some or all of the oven components to create a monolith structure. In further embodiments, the component is formed as several monolith segments spanning between supports such as oven sidewalls. The monolith component and thermally-volume-stable features can be used in combination or alone. These designs can allow the oven to be turned down below traditionally feasible temperatures while maintaining the structural integrity of the oven.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of priority to U.S. ProvisionalPatent Application No. 62/050,738 filed Sep. 15, 2014, the disclosure ofwhich is incorporated herein by reference in its entirety.

TECHNICAL FIELD

The present technology is generally directed to use of precast geometricshapes in horizontal heat recovery coke ovens, non-heat recovery cokeovens, and beehive coke ovens, for example, use of a monolith componentsto construct a horizontal coke oven.

BACKGROUND

Coke is a solid carbon fuel and carbon source used to melt and reduceiron ore in the production of steel. In one process, known as the“Thompson Coking Process,” coke is produced by batch feeding pulverizedcoal to an oven that is sealed and heated to very high temperatures for24 to 48 hours under closely-controlled atmospheric conditions. Cokingovens have been used for many years to convert coal into metallurgicalcoke. During the coking process, finely crushed coal is heated undercontrolled temperature conditions to devolatilize the coal and form afused mass of coke having a predetermined porosity and strength. Becausethe production of coke is a batch process, multiple coke ovens areoperated simultaneously.

The melting and fusion process undergone by the coal particles duringthe heating process is an important part of coking. The degree ofmelting and degree of assimilation of the coal particles into the moltenmass determine the characteristics of the coke produced. In order toproduce the strongest coke from a particular coal or coal blend, thereis an optimum ratio of reactive to inert entities in the coal. Theporosity and strength of the coke are important for the ore refiningprocess and are determined by the coal source and/or method of coking.

Coal particles or a blend of coal particles are charged into hot ovens,and the coal is heated in the ovens in order to remove volatile matter(“VM”) from the resulting coke. The coking process is highly dependenton the oven design, the type of coal, and the conversion temperatureused. Typically, ovens are adjusted during the coking process so thateach charge of coal is coked out in approximately the same amount oftime. Once the coal is “coked out” or fully coked, the coke is removedfrom the oven and quenched with water to cool it below its ignitiontemperature. Alternatively, the coke is dry quenched with an inert gas.The quenching operation must also be carefully controlled so that thecoke does not absorb too much moisture. Once it is quenched, the coke isscreened and loaded into rail cars or trucks for shipment.

Because coal is fed into hot ovens, much of the coal feeding process isautomated. In slot-type or vertical ovens, the coal is typically chargedthrough slots or openings in the top of the ovens. Such ovens tend to betall and narrow. Horizontal non-recovery or heat recovery type cokingovens are also used to produce coke. In the non-recovery or heatrecovery type coking ovens, conveyors are used to convey the coalparticles horizontally into the ovens to provide an elongate bed ofcoal.

As the source of coal suitable for forming metallurgical coal (“cokingcoal”) has decreased, attempts have been made to blend weak or lowerquality coals (“non-coking coal”) with coking coals to provide asuitable coal charge for the ovens. One way to combine non-coking andcoking coals is to use compacted or stamp-charged coal. The coal may becompacted before or after it is in the oven. In some embodiments, amixture of non-coking and coking coals is compacted to greater than 50pounds per cubic foot in order to use non-coking coal in the coke makingprocess. As the percentage of non-coking coal in the coal mixture isincreased, higher levels of coal compaction are required (e.g., up toabout 65 to 75 pounds per cubic foot). Commercially, coal is typicallycompacted to about 1.15 to 1.2 specific gravity (sg) or about 70-75pounds per cubic foot.

Horizontal Heat Recovery (“HHR”) ovens have a unique environmentaladvantage over chemical byproduct ovens based upon the relativeoperating atmospheric pressure conditions inside HHR ovens. HHR ovensoperate under negative pressure, whereas chemical byproduct ovensoperate at a slightly positive atmospheric pressure. Both oven types aretypically constructed of refractory bricks and other materials in whichcreating a substantially airtight environment can be a challenge becausesmall cracks can form in these structures during day-to-day operation.Chemical byproduct ovens are kept at a positive pressure to avoidoxidizing recoverable products and overheating the ovens. Conversely,HHR ovens are kept at a negative pressure, drawing in air from outsidethe oven to oxidize the coal's VM and to release the heat of combustionwithin the oven. It is important to minimize the loss of volatile gasesto the environment, so the combination of positive atmosphericconditions and small openings or cracks in chemical byproduct ovensallow raw coke oven gas (“COG”) and hazardous pollutants to leak intothe atmosphere. Conversely, the negative atmospheric conditions andsmall openings or cracks in the HHR ovens or locations elsewhere in thecoke plant simply allow additional air to be drawn into the oven orother locations in the coke plant so that the negative atmosphericconditions resist the loss of COG to the atmosphere.

HHR ovens have traditionally been unable to turn down their operation(e.g., their coke production) significantly below their designedcapacity without potentially damaging the ovens. This restraint islinked to temperature limitations in the ovens. More specifically,traditional HHR ovens are primarily made of silica brick. When a silicaoven is built, burnable spacers are placed between the bricks in theoven crown to allow for brick expansion. Once the oven is heated, thespacers burn away and the bricks expand into adjacency. Once HHR silicabrick ovens are heated, they are never allowed to drop below the silicabrick thermally-volume-stable temperature, the temperature above whichsilica is generally volume-stable (i.e., does not expand or contract).If the bricks drop below this temperature, the bricks start to contract.Since the spacers have burned out, a traditional crown can contract upto several inches upon cooling. This is potentially enough movement forthe crown bricks to start to shift and potentially collapse. Therefore,enough heat must be maintained in the ovens to keep the bricks above thethermally-volume-stable temperature. This is the reason why it has beenstated that a HHR oven can never be turned off Because the ovens cannotbe significantly turned down, during periods of low steel and cokedemand, coke production must be sustained. Further, it can be difficultto perform maintenance on heated HHR ovens. Other portions of the cokeoven system can suffer from similar thermal and/or structurallimitations. For example, the crown of a sole flue running under theoven floor can collapse or otherwise suffer from heaving of the ovenfloor, ground settling, thermal or structural cycling, or other fatigue.These stresses can cause bricks in the sole flue to shift and drop out.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is an isometric, partial cut-away view of a portion of ahorizontal heat recovery coke plant configured in accordance withembodiments of the present technology.

FIG. 1B is a top view of a sole flue portion of a horizontal heatrecovery coke oven configured in accordance with embodiments of thetechnology.

FIG. 1C is a front view of a monolith crown for use with the sole flueshown in FIG. 1B and configured in accordance with embodiments of thetechnology.

FIG. 2A is an isometric view of a coke oven having a monolith crownconfigured in accordance with embodiments of the technology.

FIG. 2B is a front view of the monolith crown of FIG. 2A moving betweena contracted configuration and an expanded configuration in accordancewith embodiments of the technology.

FIG. 2C is a front view of oven sidewalls for supporting a monolithcrown configured in accordance with further embodiments of thetechnology.

FIG. 2D is a front view of oven sidewalls for supporting a monolithcrown configured in accordance with further embodiments of thetechnology.

FIG. 3 is an isometric view of a coke oven having a monolith crownconfigured in accordance with further embodiments of the technology.

FIG. 4A is an isometric view of a coke oven having a monolith crownconfigured in accordance with still further embodiments of thetechnology.

FIG. 4B is a front view of the monolith crown of FIG. 4A configured inaccordance with further embodiments of the technology.

FIG. 5A is an isometric, partial cut-away view of a monolith sole flueportion of a horizontal heat recovery coke oven configured in accordancewith embodiments of the technology.

FIG. 5B is an isometric view of a section of a monolith sole flue wallfor use with the monolith sole flue shown in FIG. 5A and configured inaccordance with embodiments of the technology.

FIG. 5C is an isometric view of a blocking wall section for use with themonolith sole flue shown in FIG. 5A and configured in accordance withembodiments of the technology.

FIG. 5D is an isometric view of another section of monolith sole fluewall for use with the monolith sole flue shown in FIG. 5A and configuredin accordance with embodiments of the technology.

FIG. 5E is an isometric view of a monolith outer sole flue wall sectionwith fluid channels for use with the monolith sole flue shown in FIG. 5Aand configured in accordance with embodiments of the technology.

FIG. 5F is an isometric view of another monolith outer sole flue wallsection with open fluid channels for use with the monolith sole flueshown in FIG. 5A and configured in accordance with embodiments of thetechnology.

FIG. 5G is an isometric view of a monolith sole flue corner section foruse with the monolith sole flue shown in FIG. 5A and configured inaccordance with embodiments of the technology.

FIG. 5H is an isometric view of a monolith arch support for use with themonolith sole flue shown in FIG. 5A and configured in accordance withembodiments of the technology.

FIG. 6 is a partial isometric view of a monolith crown floor andmonolith sole flue portion of a horizontal heat recovery coke ovenconfigured in accordance with embodiments of the technology.

FIG. 7 is a block diagram illustrating a method of turning down ahorizontal heat recovery coke oven having monolith componentconstruction.

DETAILED DESCRIPTION

The present technology is generally directed to horizontal heat recoverycoke ovens having monolith component construction. In some embodiments,a HHR coke oven includes a monolith crown that spans the width of theoven between opposing oven sidewalls, a monolith wall that extends theheight and length of the coke oven, and/or a monolith floor that extendsthe length and width of the coke oven. The monolith components expandupon heating and contracts upon cooling as a single structure. Infurther embodiments, the monolith components comprise athermally-volume-stable material. In various embodiments, the monolithcomponent and thermally-volume-stable features can be used incombination or alone. These designs can allow the oven to be turned downbelow traditionally-feasible temperatures while maintaining thestructural integrity of the monolith components.

Specific details of several embodiments of the technology are describedbelow with reference to FIGS. 1A-7. Other details describing well-knownstructures and systems often associated with coke ovens have not beenset forth in the following disclosure to avoid unnecessarily obscuringthe description of the various embodiments of the technology. Many ofthe details, dimensions, angles, and other features shown in the Figuresare merely illustrative of particular embodiments of the technology.Accordingly, other embodiments can have other details, dimensions,angles, and features without departing from the spirit or scope of thepresent technology. A person of ordinary skill in the art, therefore,will accordingly understand that the technology may have otherembodiments with additional elements, or the technology may have otherembodiments without several of the features shown and described belowwith reference to FIGS. 1A-7.

FIG. 1A is an isometric, partial cut-away view of a portion of ahorizontal heat recovery (“HHR”) coke plant 100 configured in accordancewith embodiments of the technology. The plant 100 includes a pluralityof coke ovens 105. Each oven 105 can include an open cavity defined by afloor 160, a front door 165 forming substantially the entirety of oneside of the oven, a rear door (not shown) opposite the front door 165forming substantially the entirety of the side of the oven opposite thefront door, two sidewalls 175 extending upwardly from the oven floor 160intermediate the front door 165 and rear door, and a crown 180 thatforms the top surface of the open cavity of an oven chamber 185. A firstend of the crown 180 can rest on a first sidewall 175 while a second endof the crown 180 can rest on an opposing sidewall 175 as shown. Adjacentovens 105 can share a common sidewall 175.

In operation, volatile gases emitted from the coal positioned inside theoven chamber 185 collect in the crown 180 and are drawn downstream inthe overall system into downcommer channels 112 formed in one or bothsidewalls 175. The downcommer channels 112 fluidly connect the ovenchamber 185 with a sole flue 116 positioned beneath the oven floor 160.The sole flue 116 includes a plurality of side-by-side runs 117 thatform a circuitous path beneath the oven floor 160. While the runs 117 inFIG. 1A are shown to be substantially parallel to a longitudinal axis ofthe oven 105 (i.e., parallel to the sidewalls 175), in furtherembodiments, the sole flue 116 can be configured such that at least somesegments of the runs 117 are generally perpendicular to the longitudinalaxis of the oven 105 (i.e., perpendicular to the sidewalls 175), instill further embodiments, the sole flue 116 can be configured such thatall or some of the runs 117 are nonperpendicular to the longitudinalaxis and or are generally serpentine. This arrangement is illustrated inFIG. 1B and is discussed in further detail below. Volatile gases emittedfrom the coal can be combusted in the sole flue 116, thereby generatingheat to support the reduction of coal into coke. The downcommer channels112 are fluidly connected to chimneys or uptake channels 114 formed inone or both sidewalls 175.

From time to time, the downcommer channels 112 may require inspection orservice to ensure that the oven chamber 185 remains in open fluidcommunication with the sole flue 116 positioned beneath the oven floor160. Accordingly, in various embodiments, downcommer covers 118 arepositioned over openings in the upper end portions of the individualdowncommer channels 112. In some embodiments, the downcommer covers 118may be provided as a single, plate structure. In other embodiments, suchas depicted in FIG. 1A, the downcommer covers 118 may be formed from aplurality of separate cover members that are positioned closelyadjacent, or secured with, one another. Certain embodiments of thedowncommer covers 118 include one or more inspection openings 120 thatpenetrate central portions of the downcommer cover 118. While depictedas being round, it is contemplated that the inspection openings 120 maybe formed to be nearly any curvilinear, or polygonal shape, desired forthe particular application. Plugs 122 are provided to have shapes thatapproximate those of the inspection openings 120. Accordingly, the plugs122 may be removed for visual inspection or repair of the downcommerchannels 112 and returned in order to limit the unintentional escape ofvolatile gases. In additional embodiments a liner may extend the fulllength of the channel to interface with the inspection opening. Inalternative embodiments, the liner may extend only a portion of thechannel length.

Coke is produced in the ovens 105 by first loading coal into the ovenchamber 185, heating the coal in an oxygen-depleted environment, drivingoff the volatile fraction of coal, and then oxidizing the VM within theoven 105 to capture and utilize the heat given off The coal volatilesare oxidized within the ovens 105 over an extended coking cycle andrelease heat to regeneratively drive the carbonization of the coal tocoke. The coking cycle begins when the front door 165 is opened and coalis charged onto the oven floor 160. The coal on the oven floor 160 isknown as the coal bed. Heat from the oven (due to the previous cokingcycle) starts the carbonization cycle. Roughly half of the total heattransfer to the coal bed is radiated down onto the top surface of thecoal bed from the luminous flame of the coal bed and the radiant ovencrown 180. The remaining half of the heat is transferred to the coal bedby conduction from the oven floor 160, which is convectively heated fromthe volatilization of gases in the sole flue 116. In this way, acarbonization process “wave” of plastic flow of the coal particles andformation of high strength cohesive coke proceeds from both the top andbottom boundaries of the coal bed.

Typically, each oven 105 is operated at negative pressure so air isdrawn into the oven during the reduction process due to the pressuredifferential between the oven 105 and the atmosphere. Primary air forcombustion is added to the oven chamber 185 to partially oxidize thecoal volatiles, but the amount of this primary air is controlled so thatonly a portion of the volatiles released from the coal are combusted inthe oven chamber 185, thereby releasing only a fraction of theirenthalpy of combustion within the oven chamber 185. The primary air isintroduced into the oven chamber 185 above the coal bed. The partiallycombusted gases pass from the oven chamber 185 through the downcommerchannels 112 into the sole flue 116 where secondary air is added to thepartially combusted gases. As the secondary air is introduced, thepartially combusted gases are more fully combusted in the sole flue 116,thereby extracting the remaining enthalpy of combustion, which isconveyed through the oven floor 160 to add heat to the oven chamber 185.The fully or nearly fully combusted exhaust gases exit the sole flue 116through the uptake channels 114. At the end of the coking cycle, thecoal has coked out and has carbonized to produce coke. The coke can beremoved from the oven 105 through the rear door utilizing a mechanicalextraction system. Finally, the coke is quenched (e.g., wet or dryquenched) and sized before delivery to a user.

As will be discussed in further detail below with reference to FIGS.2A-4B, in several embodiments, the crown 180, the floor 160, and/or thesidewalls 175 comprise a monolith element structure or precast shape.The monolith crown 160 is configured to span all or a portion of thedistance between the monolith sidewalls 175 and/or including themonolith sidewalls. In further embodiments, the monolith crown caninclude some or all of the monolith sidewalls 175 on one or both sidesof the monolith crown. In still further embodiments, the monolith floor160 can include some or all of the monolith sidewalls 175 on one or bothsides of the monolith crown 160. For example, the monolith crown 180 cancomprise a single segment that spans between the sidewalls 175 or cancomprise two, three, four, or more segments that meet between thesidewalls 175 and in combination span between the sidewalls 175, or cancomprise a monolith crown with integral monolith sidewalls 175.Similarly, for example, the monolith floor 160 can comprise a singlesegment that spans between the sidewalls 175 or can comprise two, three,four, or more segments that meet between the sidewalls 175 and incombination span between the sidewalls 175, or can comprise a monolithfloor with integral monolith sidewalls 175. In still furtherembodiments, the monolith crown 160, the monolith sidewalls 175, and themonolith floor 160 may form one monolith structure and may be cast inplace or may be pre-cast and then moved into place. The monolithstructure enables the crown 180 to expand upon oven heating and retractupon cooling without allowing individual bricks to contract and fallinto the oven chamber 185, causing the monolith crown 180 to collapse.The monolith crown 180 can accordingly allow the oven 105 to be shutdown or turned down below traditionally feasible temperatures for agiven crown material. As discussed above, some materials, like silica,become generally thermally-volume-stable above certain temperatures(i.e., around 1,200° F. for silica). Using a monolith crown 180, asilica brick oven can be turned down below 1,200° F. Other materials,such as alumina, have no thermally-volume-stable upper limit (i.e.,remain volume-unstable or expandable), and the monolith crown 180 allowsfor the use of these materials without collapse from coolingcontraction. In other embodiments, other materials or combinations ofmaterials can be used for the monolith crown, with different materialshaving different associated thermally-volume-stable temperatures.Further, the monolith crown 180 can be quickly installed, as the wholearch can be lifted and placed as a single structure. Further, by usingmonolith segments instead of numerous individual bricks, the monolithcrown 180 can be built in shapes different from the traditionalarch—such as a flat or straight-edged shape. Some of these designs areshown in FIGS. 3 and 4A. In various embodiments, the monolith crown 180can be precast or pre-formed or formed on site. The monolith crown 180can have various widths (i.e., from sidewall-to-sidewall) in differentembodiments or can include the sidewall in alternative embodiments. Insome embodiments, the monolith crown 180 width is about 3 feet orgreater, while in particular embodiments, the width is 12-15 feet. Inother embodiments, the precast shape used in the coke oven in accordancewith this disclosure is of various complex geometrical shapes, includingall three dimensional shapes with the express exclusion of a simplebrick shape.

In some embodiments, the monolith crown 180 is at least partially madeof a thermally-volume-stable material such that upon heating or coolingthe oven chamber 185, the monolith crown 180 does not adjust inposition. As with an overall monolith oven design, a monolith crown 180made of a thermally-volume-stable material allows the oven 105 to beshut down or turned down without individual bricks in the crown 180contracting and collapsing into the oven chamber 185. While the term“thermally-volume-stable material” is used herein, this term can referto materials that are zero-expansion, zero-contraction,near-zero-expansion, and/or near-zero-contraction, or a combination ofthese characteristics, upon heating and/or cooling. In some embodiments,the thermally-volume-stable materials can be precast or pre-fabricatedinto designed shapes, including as individual shapes or monolithsegments. Further, in some embodiments, the thermally-volume-stablematerials can be repeatedly heated and cooled without affecting theexpandability characteristics of the material, while in otherembodiments the material can be heated and/or cooled only once beforeundergoing a phase or material change that affects subsequentexpandability characteristics. In a particular embodiment, thethermally-volume-stable material is a fused silica material, zirconia,refractory material, or a ceramic material. In further embodiments,other portions of the oven 105 additionally or alternately can be formedof thermally-volume-stable materials. For example, in some embodiments,the lintel for the door 165 comprises such a material. When usingthermally-volume-stable materials, traditional-sized bricks or amonolith structure can be used as the crown 180.

In some embodiments, the monolith or thermally-volume-stable designs canbe used at other points in the plant 100, such as over the sole flue116, as part of the oven floor 160 or sidewalls 175, or other portionsof the oven 105. In any of these locations, the monolith orthermally-volume-stable embodiments can be used as an individualstructure or as a combination of sections. For example, a crown 180 oroven floor 160 can comprise one monolith component, multiple monolithsegments and/or multiple segments made of thermally-volume-stablematerial. In another embodiment, as shown in FIG. 1A, a monolith segmentover the sole flue 116 comprises a plurality of side-by-side arches,each arch covering a run 117 of the sole flue 116. Since the archescomprise a single structure, they can expand and contract as a singleunit. In further embodiments (as will be discussed in further detailbelow), the crown of the sole flue can comprise other shapes, such as aflat top and such other shapes may be a single monolith segment or aplurality of monolith segments. In still further embodiments, themonolith sole flue crown comprises individual monolith segments (e.g.,individual arches or flat portions) that each span only one run 117 ofthe sole flue 116.

FIG. 1B is a top view of a monolith sole flue 126 of a horizontal heatrecovery coke oven configured in accordance with embodiments of thetechnology. The monolith sole flue 126 has several features generallysimilar to the monolith sole flue 116 described above with reference toFIG. 1A. For example, the monolith sole flue includes a serpentine orlabyrinth pattern of runs 127 configured for communication with a cokeoven (e.g., the coke oven 105 of FIG. 1A) via the downcommer channels112 and uptake channels 114. Volatile gases emitted from the coalpositioned inside a coke oven chamber are drawn downstream into thedowncommer channels 112 and into the sole flue 126. Volatile gasesemitted from the coal can be combusted in the sole flue 126, therebygenerating heat to support the reduction of coal into coke. Thedowncommer channels 112 are fluidly connected to chimneys or uptakechannels 114, which draw fully or nearly fully combusted exhaust gasesfrom the sole flue 126.

In FIG. 1B, at least some segments of the runs 127 are generallyperpendicular to the longitudinal axis of the oven 105 (i.e.,perpendicular to the sidewalls 175 shown in FIG. 1A). Alternatively, thesole flue pathway may be serpentine or may include directional flowbaffles. In still further embodiments, the sole flue 126 may be a singlemonolith segment or multiple monolith segments adjacent to and/orinterlocked together. As with the monolith sole flue 116, shown in FIG.1A, the monolith sole flue 126 of FIG. 1B can include a monolith crownportion that spans individual runs 127 or a plurality of runs 127. Themonolith sole flue crown can comprise a flat monolith segment, a singlemonolith arch, a plurality of adjacent monolith arches, a combination ofthese monolith shapes, or other monolith shapes. Further, the monolithsole flue crown can span and/or follow the turns or curves of the soleflue serpentine pathway of runs 127.

FIG. 1C is a front view of a monolith crown 181 for use with themonolith sole flue 126 shown in FIG. 1B and configured in accordancewith embodiments of the technology. In the illustrated embodiment, themonolith crown 181 comprises a plurality of adjacent arched portions 181a, 181 b having a flat top 183. Each portion 181 a, 181 b can be used asa monolith crown for an individual run in the sole flue 126. Further,the flat monolith top 183 can comprise a monolith floor or subfloor forthe oven chamber 185 described above with reference to FIG. 1A. In someembodiments, a layer of bricks can be placed on top of the flat monolithtop 183.

In various embodiments, the monolith crown 181 can comprise a singlemonolith segment or a plurality of individual segments (e.g., theindividual arched portions 181 a, 181 b) that are separated by anoptional joint 186 shown in broken line. Accordingly, a single monolithcrown 181 can cover one run or a plurality of adjacent runs in themonolith sole flue 126. As mentioned above, in further embodiments, themonolith crown 181 can have shapes other than an arched underside with aflat top. For example, the crown 181 can be entirely flat, entirelyarched or curved, or other combinations of these characteristics. Whilethe monolith crown 181 has been described for use with the monolith soleflue 126 of FIG. 1B, it could similarly be used with the sole flue 116or coking chamber 185 shown in FIG. 1A.

FIG. 2A is an isometric view of a coke oven 205 having a monolith crown280, monolith walls 275 and monolith floor 260 configured in accordancewith embodiments of the technology. The oven 205 is generally similar tothe oven 105 described above with reference to FIG. 1. For example, theoven 205 includes the monolith oven floor 260 and opposing monolithsidewalls 275. The monolith crown 280 comprises a monolith structure,wherein the monolith crown 280 extends between the monolith sidewalls275 and/or the monolith crown 280 and sidewalls 275 are one monolithstructure. In the illustrated embodiment, the monolith crown 280comprises a plurality of monolith crown segments 282 generally adjacentto one another and aligned along the length of the oven 205 between thefront and back of the oven 205. While three segments 282 areillustrated, in further embodiments, there can be more or fewer segments282. In still further embodiments, the crown 280 comprises a singlemonolith structure extending from the front of the oven 205 to the back.In some embodiments, multiple segments 282 are used to easeconstruction. The individual segments can meet joints 284. In someembodiments, the joints 284 are filled with refractory material, such asrefractory blanket, mortar, or other suitable material, to prevent airin-leakage and unintentional exhaust. In still further embodiments, aswill be discussed with reference to FIG. 4 below, the monolith crown 280can comprise multiple lateral segments between the sidewalls 275 thatmeet or join over the oven floor 260 to form a monolith structure.

The monolith sidewalls 275 comprise a monolith structure, wherein themonolith sidewalls 275 extend from the monolith floor 260 to themonolith crown 280 as one monolith structure. In the illustratedembodiment, the monolith sidewalls 275 comprise a plurality of monolithwall segments 277 generally adjacent to one another and aligned alongthe length of the oven 205 between the front and back of the oven 205.While three segments 277 are illustrated, in further embodiments, therecan be more or fewer segments 277. In still further embodiments, thewalls 275 comprises a single monolith structure extending from the frontof the oven 205 to the back. In some embodiments, multiple segments 277are used to ease construction. The individual segments can meet joints279. In some embodiments, the joints 279 are filled with refractorymaterial, such as refractory blanket, mortar, or other suitablematerial, to prevent air in-leakage and unintentional exhaust. In stillfurther embodiments, as will be discussed with reference to FIG. 4below, the monolith walls 275 can comprise multiple lateral segmentsbetween the monolith crown 280 and the oven floor 260 to form a monolithstructure.

The monolith floor 260 comprises a monolith structure, wherein themonolith floor 260 extends between the monolith sidewalls 275 and/or themonolith floor 260 and sidewalls 275 are one monolith structure. In theillustrated embodiment, the monolith floor 260 comprises a plurality ofmonolith floor segments 262 generally adjacent to one another andaligned along the length of the oven 205 between the front and back ofthe oven 205. While three segments 262 are illustrated, in furtherembodiments, there can be more or fewer segments 262. In still furtherembodiments, the monolith floor 260 comprises a single monolithstructure extending from the front of the oven 205 to the back. In someembodiments, multiple segments 262 are used to ease construction. Theindividual segments can meet joints 264. In some embodiments, the joints264 are filled with refractory material, such as refractory blanket,mortar, or other suitable material, to prevent air in-leakage andunintentional exhaust. In still further embodiments, as will bediscussed with reference to FIG. 4 below, the monolith floor 260 cancomprise multiple lateral segments between the sidewalls 275 that meetor join under the monolith crown 280 to form a monolith structure.

FIG. 2B is a front view of the monolith crown 280 of FIG. 2A movingbetween a contracted configuration 280 a and an expanded configuration280 b in accordance with embodiments of the technology. As discussedabove, traditional crown materials expand upon oven heating and contractupon cooling. This retraction can create space between individual ovenbricks and cause bricks in the crown to collapse into the oven chamber.Using monolith segments, for example, a monolith crown, however, themonolith crown 280 expands and contracts as a single structure and doesnot collapse upon cooling. Similarly, monolith floor 260, monolith walls275, or combined monolith segments will expand and contract as a singlestructure.

The design of the oven 205 provides structural support for suchexpansion and contraction between monolith shapes or structures uponheating and cooling. More specifically, the monolith sidewalls 275 thatsupport the monolith crown 280 can have a width W that is sufficientlygreater than the width of the monolith crown 280 to fully support themonolith crown 280 as the monolith crown 280 moves laterally between thecontracted 280 a and expanded 280 b configurations. For example, thewidth W can be at least the width of the monolith crown 280 plus thedistance D of expansion. Therefore, when the monolith crown 280 expandsor is translated laterally outward upon heating, and contracts andtranslates laterally inward again upon cooling, the monolith sidewalls275 maintain support of the monolith crown 280. The monolith crown 280can likewise expand or translate longitudinally outward upon heating,and contract and translate longitudinally inward upon cooling. The frontand back walls (or door frames) of the oven 205 can accordingly be sizedto accommodate this shifting.

In further embodiments, the monolith crown 280 can rest on a crownfooting other than directly on the monolith sidewalls 275. Such afooting can be coupled to or be an independent structure of thesidewalls 275. In still further embodiments, the entire oven may be madeof expanding and contracting material and can expand and contract withthe crown 280, and may not require sidewalls having a width as large asthe width W shown in FIG. 2B because the monolith crown 280 staysgenerally aligned with the expanding monolith sidewalls 275 upon heatingand cooling. Similarly, if both the monolith crown 280 and monolithsidewalls 275 are made of a thermally-volume-stable material, then themonolith sidewalls 275 can stay generally aligned with the monolithcrown 280 upon heating and cooling, and the monolith sidewalls 275 neednot be substantially wider (or even as wide) as the monolith crown 280.In some embodiments, the sidewalls 275 (monolith or brick), front orback door frames, and/or crown 280 can be retained in place via acompression or tension system, such as a spring-load system. In aparticular embodiment, the compression system can include one or morebuckstays on an exterior portion of the sidewalls 275 and configured toinhibit the sidewalls 275 from outward movement. In further embodiments,such a compression system is absent.

FIG. 2C is a front view of oven monolith sidewalls 177 for supporting amonolith crown 281 configured in accordance with further embodiments ofthe technology. The monolith sidewalls 177 and monolith crown 281 aregenerally similar to the monolith sidewalls 175 and monolith crown 280shown in FIG. 2B. In the embodiment shown in FIG. 2C, however, themonolith sidewalls 177 and monolith crown 281 have an angled or slantedinterface 287. Thus, when the monolith crown 281 expands distance D uponheating (i.e., translates from position 281 a to position 281 b), themonolith crown 281 translates along the slanted surface of the top ofthe monolith sidewall 177 following the pattern of the interface 287.Similarly, when the monolith sidewall 177 expands upon heating in heightH, the monolith crown 281 translates along the slanted surface of thetop of the monolith sidewall 177 following the pattern of the interface287 and accommodating for differential thermal expansion.

In other embodiments, the monolith crown 281 and monolith sidewalls 177can interface in other patterns, such as recesses, slots, overlappingportions, and/or interlocking features. For example, FIG. 2D is a frontview of oven monolith sidewalls 179 for supporting a monolith crown 283configured in accordance with further embodiments of the technology. Themonolith sidewalls 179 and monolith crown 283 are generally similar tothe monolith sidewalls 175 and monolith crown 280 shown in FIG. 2B. Inthe embodiment shown in FIG. 2D, however, the monolith sidewalls 179 andmonolith crown 283 have a stepped or zigzag interface 289. Thus, whenthe monolith crown 283 expands distance D upon heating (i.e., translatesfrom position 283 a to position 283 b), the monolith crown 283translates along the stepped surface of the top of the monolith sidewall179 following the pattern of the interface 289.

Similarly, in other embodiments, the monolith floor and monolithsidewalls can interface in similar patterns, such as recesses, slots,overlapping portions, and/or interlocking features. For example, themonolith sidewalls may be supported by the monolith floor configured inaccordance with further embodiments of the technology. The monolithsidewalls and monolith floor are generally similar to the monolithsidewalls 175 and monolith floor 260 shown in FIG. 2B. However, themonolith sidewalls and monolith floor may have a stepped or zigzaginterface similar to the monolith sidewalls and monolith crown interfaceshown in the embodiment shown in FIG. 2D. In still further embodiments,monolith components can include a variety of indent/detent, tongue andgroove, angled or similar interfaces. Still other interface patternsinclude recesses, slots, overlapping portions, and/or interlockingfeatures.

FIG. 3 is an isometric view of a coke oven 305 having a monolith crown380 configured in accordance with further embodiments of the technology.Because the monolith crown 380 is preformed, it can take on shapes otherthan the traditional arch. In the illustrated embodiment, for example,the monolith crown 380 comprises a generally flat surface. This designcan provide for minimal material costs. In other embodiments, othermonolith crown shapes can be employed to improve gas distribution in theoven 305, to minimize material costs, or for other efficiency factors.Further, as shown in FIG. 3, the monolith crown 380, monolith floors360, and monolith walls 375 may combine to form a monolith structure ora monolith coke oven.

FIG. 4A is an isometric view of a coke oven 405 having a monolith crown480 configured in accordance with other embodiments of the technology.The crown 405 comprises a plurality (e.g., two) monolith portions 482that meet at a joint 486 over the oven floor 160. The joint 486 can besealed and/or insulated with any suitable refractory material ifnecessary. In various embodiments, the joint(s) 486 can be centered onthe crown 480 or can be off-center. The monolith portions 482 can be thesame size or a variety of sizes. The monolith portions 482 can begenerally horizontal or angled (as shown) relative to the oven floor160. The angle can be selected to optimize air distribution in the ovenchamber. There can be more or fewer monolith portions 482 in furtherembodiments. Further, the monolith crown, monolith floors, and monolithwalls may combine to form a monolith structure or a monolith coke oven.

FIG. 4B is a front view of the monolith crown 480 of FIG. 4A configuredin accordance with further embodiments of the technology. As shown inFIG. 4B, the monolith portions 482 can include an interfacing feature atthe joint 486 to better secure the monolith portions 482 to one another.For example, in the illustrated embodiment, the joint 486 comprises apin 492 on one monolith portion 482 configured to slide into andinterface with a slot 490 on the adjacent monolith portion 482. Infurther embodiments, the joint 486 can comprise other recesses, slots,overlapping features, interlocking features, or other types ofinterfaces. In still further embodiments, mortar is used to seal or fillthe joint 486. In still further embodiments, the monolith crown,monolith floors, and monolith walls may combine to form a monolithstructure or a monolith coke oven.

While the illustrated interfacing feature is along a joint 486 that isgenerally parallel to the sidewalls 175, in further embodiments, theinterfacing feature can be used at a joint that is generallyperpendicular to the sidewalls 175. For example, any of the interfacingfeatures described above could be used at the joints 284 between thecrown segments 282 of FIG. 2A. Thus, the interfacing features can beused at any joint in the crown 480, regardless of whether monolithportions are orientated side-to-side or front-to-back over the ovenfloor. In accordance with aspects of the disclosure, the crown orprecast section may be an oven crown, an upcommer arch, a downcommerarch, a J-piece, a single sole flue arch or multiple sole flue arches, adowncommer cleanout, curvilinear corner sections, and/or combinedportions of any of the above sections. In some embodiments, the monolithcrown is formed at least in part with a thermally-volume-stablematerial. In further embodiments, the monolith crown is formed as amonolith or several monolith segments spanning between supports such asoven sidewalls. In still further embodiments, the monolith crown isformed to span multiple ovens. In still further embodiments, themonolith crown includes integral monolith sidewalls.

FIG. 5A depicts a partial, cut-away view of a monolith sole flue 516portion of a horizontal heat recovery coke oven configured in accordancewith embodiments of the technology. The downcommer channels 112 fluidlyconnect the oven chamber 185 with the monolith sole flue 516. Themonolith sole flue 516 includes a plurality of side-by-side runs 517beneath the oven floor. As discussed with respect to the oven 105, theruns 517 in FIG. 5A are shown to be substantially parallel to alongitudinal axis of the oven. However, in other embodiments, themonolith sole flue 516 can be configured such that at least somesegments of the runs 517 are generally perpendicular to the longitudinalaxis of the oven. In still further embodiments, the monolith sole fluecan be configured such that at least some segments of the funs 517 arenonperpendicular or are serpentine.

The runs 517 are separated by monolith sole flue walls 520. While it iscontemplated that the monolith sole flue walls 520 could be formed in aone-piece construction, such as a single casting or cast-in-place unit.However, in other embodiments, a plurality of monolith sole flue wallsegments 522 couple with one another to define the individual monolithsole flue walls 520. With reference to FIGS. 5B and 5D, the individualmonolith sole flue wall segments 522 may be provided with a ridge 524,extending outwardly in a vertical fashion from one end. Similarly, themonolith sole flue wall segments 522 may include a groove 526 thatextends inwardly in a vertical fashion at the opposite end. In thismanner, opposing monolith sole flue wall segments 522 may be positionedclosely adjacent one another so that the ridge 524 of one monolith soleflue wall segment 522 is disposed within the groove 526 of the adjacentmonolith sole flue wall segment 522. In addition to, or in place of, themating ridge 524 and groove 526, the monolith sole flue wall segments522 may be provided with a notch 528 at one end and a projection 530that extends from the opposite end. The notch 528 and projection 530 areshaped and positioned so that one sole monolith flue wall segment 522may couple with an adjacent monolith sole flue wall segment 522 throughthe interlocking of the notch 528 and the projection 530. As will beappreciated by one skilled in the art, alternative geometric,reciprocating or locking systems are contemplated within the scope ofthis disclosure.

Volatile gases emitted from the coal in the oven are directed to thesole flue 516 through downcommer channels 512, which are fluidlyconnected to chimneys or uptake channels 514 by the sole flue 516. Thevolatile gases are directed along a circuitous path along the sole flue516. With reference to FIG. 5A, the volatile gases exit the downcommerchannels 512 and are directed along a fluid pathway through the runs517. In particular, blocking wall section 532 is positioned to extendtransversely between the sole flue wall 520 and the outer sole flue wall534, between the downcommer channels 512 and the uptake channels 514. Inat least one embodiment, a sole flue wall segment 523 includes a ridge536 that extends outwardly in a vertical fashion from the sole flue wallsegment 523. One end of the blocking wall section 532 includes a groove538 that extends inwardly in a vertical fashion. In this manner, thesole flue wall segment 523 may be positioned closely adjacent theblocking wall section 532 so that the ridge 536 is disposed within thegroove 538 to secure the position of the opposing structures with oneanother. In this manner, the volatile gases are substantially preventedfrom short circuiting the fluid pathway from the downcommer channels 512and the uptake channels 514.

As the volatile gases travel along the fluid pathway through the soleflue 516, they are forced around end portions of the sole flue walls520, which may stop short of meeting with sole flue end walls 540. Thegap between the end portion of the sole flue walls 520 and the sole flueend walls 540 are, in various embodiments, provided with arch sections542 to span the gap. In some embodiments, the arch sections 542 may beU-shaped, providing a pair of opposing legs to engage the sole fluefloor 543 and an upper end portion to engage the oven floor. In otherembodiments, the arch section 542 may be an arched or a flatcantilevered section integrated with and extending from the sole fluewall 520. In other embodiments, such as those depicted in FIGS. 5A and5H, the arch sections 542 are J-shaped, having an upper end portion 544with an arched lower surface 546 and an upper surface 548 that is shapedto engage the oven floor. A single leg 550 extends downwardly from oneend of the upper end portion 544 to engage the sole flue floor 543. Aside portion of the leg 550 is positioned closely adjacent the free endportion of the sole flue wall 520. A free end portion 552 of the upperend portion 544, opposite the leg 550, in some embodiments, engages ananchor point 554 on the sole flue wall 520 to support that side of thearch section 542. In some embodiments, the anchor point 554 is a recessor a notch formed in the sole flue wall 520. In other embodiments, theanchor point 554 is provided as a ledge portion of an adjacentstructure, such as the sole flue end wall 540. As the volatile gasestravel around end portions of the sole flue walls 520, the volatilegases encounter corners, in certain embodiments, where the sole flue endwalls 540 meet outer sole flue walls 534 and sole flue walls 520. Suchcorners present, by definition, opposing surfaces that engage thevolatile gases and induce turbulence that disrupt the smooth, laminarflow of the volatile gases. Accordingly, some embodiments of the presenttechnology include sole flue corner sections 556 in the corners toreduce the disruption of the volatile gas flow. With reference to FIG.5G, embodiments of the sole flue corner sections 556 include an angularrearward face 558 that is shaped to engage the corner areas of the soleflue 516. Opposite, forward faces 560 of the sole flue corner sections556 are shaped to be curvilinear or concave. In other embodiments thecorner section is a curved pocket. In operation, the curvilinear shapereduces dead flow zones and smooths out transitions in flow. In thismanner, turbulence in the volatile gas flow may be reduced as the fluidpathway travels the corner areas of the sole flue 516. Top surfaces ofthe sole flue corner sections 556 may be shaped to engage the oven floorfor additional support.

In various prior art coking ovens, the outer sole flue walls are formedfrom brick. Accordingly, the downcommer channels and the uptake channelsthat extend through the outer sole flue walls are formed with flatopposing walls that meet at corners. Accordingly, the fluid pathwaythrough the downcommer channels and the uptake channels is turbulent andreduces optimal fluid flow. Moreover, the irregular surfaces of thebrick and the angular geometry of the downcommer channels and the uptakechannels promote the build-up of debris and particulate over time, whichfurther restricts fluid flow. With reference to FIG. 5A and FIG. 5E,embodiments of the present technology form at least portions of theouter monolith sole flue walls 534 with monolith channel blocks 562. Insome embodiments, the channel blocks 562 include one or more channels564, having open ends that penetrate widths of the monolith channelblocks 562 and closed sidewalls. In other embodiments, monolith channelblocks 566 include one or more open channels 568 that have open endsthat penetrate widths of the monolith channel blocks 566 and sidewallsthat are open to one side of the monolith channel blocks 566 to definechannel openings 570. In various embodiments, the monolith channelblocks 566 are positioned at the sole flue floor level. Channel blocks562 are positioned on top of the monolith channel blocks 566 so thatends of the channels 564 and ends of the open channels 568 are placed inopen fluid communication with one another. In this orientation, thechannel openings 570 for one set of monolith channel blocks 566 mayserve as the outlet for downcommer channels 512. Similarly, the channelopenings 570 for another set of channel blocks 566 may serve as theinlet for the uptake channels 514. More than one channel block 562 maybe positioned on top of each channel block 566, depending on the desiredheight of the outer sole flue wall 534 and the sole flue 516.

With reference to FIG. 6, the runs 517 of the sole flue 516 may becovered by an oven floor 660, which can comprise multiple monolithsegments 662 made of thermally volume-stable material. In particular, asshown in FIG. 6, a monolith over the sole flue 516 is formed from aplurality of side-by-side arches, each arch covering a run 517 of thesole flue 516. Lower end portions 664 of the monolith segments 662 arepositioned on upper surfaces of the sole flue walls 520 and outer soleflue walls 534. According to further aspects, a planar monolith layer ora segmented brick layer may cover the top portion of the monolithsegments 662. Further, as discussed previously with regard to otheraspects of the present technology, the entire oven may be made ofexpanding and contracting monolith components or structures material sothat some or all of the structural components of the oven can expand andcontract with one another. Accordingly, if the monolith segments 662,sole flue walls 520, and the outer sole flue walls 534 are made of athermally-volume-stable material, then the monolith segments 662, soleflue walls 520, and the outer sole flue walls 534 can stay generallyaligned with one another upon heating and cooling. It is contemplated,however, that in certain applications, that one or more of the monolithsegments 662, sole flue walls 520, and the outer sole flue walls 534could be made from materials other than thermally-volume-stablematerial. Such instances may arise during a repair or retrofit of anexisting coking oven with precast structural components. In furtherapplications, the one or more of the monolith segments, sole flue walls,and outer flue walls could be made from alumina or other thermallyexpandable materials. It is similarly contemplated that some or all ofthe other components described herein, such as downcommer cover 118, theblocking wall sections 532, sole flue end walls 540, arch sections 542,sole flue corner sections 556, channel blocks 562, and channel blocks566 could be formed from a thermally-volume-stable material and/or couldbe lined with thermally-volume-stable material.

In accordance with aspects of the disclosure, the oven may beconstructed of monolith precast interlocking or interfacing shapesforming a precast oven. For example, the monolith crown with integralsidewalls may sit on a precast floor with monolith sole flue walls, thusthe entire oven may be constructed of a plurality of precast shapes asshown in FIG. 1A. In alternative embodiments, the entire oven may beconstructed of one precast piece. In further embodiments, the oven maybe constructed of one or more precast shapes interfacing with individualbricks to form a hybrid oven construction. Aspects of the hybrid ovenconstruction may be particularly efficient in oven repairs as furthershown in the figures.

FIG. 7 is a block diagram illustrating a method 700 of turning down ahorizontal heat recovery coke oven. The method may include use of aprecast monolithic component to replace brick structures or may includea horizontal coke oven built of precast monolithic sections. At block710, the method 700 includes forming a coke oven structure having anoven crown over an oven chamber. The crown or precast section may be anoven crown, an upcommer arch, a downcommer arch, a J-piece, a singlesole flue arch or multiple sole flue arches, a downcommer cleanout,curvilinear corner sections, and/or combined portions of any of theabove sections. In some embodiments, the crown is formed at least inpart with a thermally-volume-stable material. In further embodiments,the crown is formed as a monolith (or several monolith segments)spanning between supports such as oven sidewalls. In furtherembodiments, the method 700 includes forming a coke oven structurehaving a plurality of monolithic sections.

At block 720, the method 700 includes heating the coke oven chamber. Insome embodiments, the oven chamber is heated above thethermally-volume-stable temperature of a given material (e.g., above1,200° F. in the case of a silica oven). The method 700 then includesturning down the coke oven below a thermally-volume-stable temperatureat block 730. For materials having a thermally-volume-stabletemperature, like silica, this comprises dropping the oven temperaturebelow this temperature (e.g., below 1,200° F. in the case of a silicaoven). For thermally-volume-stable materials, like fused silica, ormaterials not having a thermally-volume-stable temperature, likealumina, the step of turning down the coke oven below athermally-volume-stable temperature comprises turning down the oventemperature to any lesser temperature. In particular embodiments,turning down the coke oven comprises turning off the coke oven entirely.In further embodiments, turning down the coke oven comprises turningdown the coke oven to a temperature of about 1,200° F. or less. In someembodiments, the coke oven is turned down to 50% or less of the maximumoperating capacity. At block 740, the method 700 further includesmaintaining the coke oven structure, including the integrity of the ovencrown. The oven is thus turned down without collapse as experienced intraditional ovens. In some embodiments, the oven is turned down withoutcausing significant crown contraction. The method described above can beapplied to a coking chamber, sole flue, downcommer, upcommer, walls,floors, or other portions of the oven.

EXAMPLES

The following Examples are illustrative of several embodiments of thepresent technology.

1. A coke oven chamber, comprising:

A monolith sole flue section having a serpentine path therein;

a front wall extending vertically upward from the monolith sole fluesection and a back wall opposite the front wall;

a first sidewall extending vertically upward from the floor between thefront wall and the back wall and a second sidewall opposite the firstsidewall; and

a monolith crown positioned above the monolith sole flue section andspanning from the first sidewall to the second sidewall.

2. The coke oven chamber of claim 1 wherein the monolith crown comprisesa plurality of monolith portions spanning from the first sidewall to thesecond sidewall, wherein the plurality of monolith portions arepositioned generally adjacent to one another between the front wall andthe back wall.

3. The coke oven chamber of claim 1 wherein:

at least one of the monolith crown or sidewalls are configured totranslate, contract, or expand by an adjustment amount upon heating orcooling the coke oven chamber;

the monolith crown comprises a first end portion resting on the firstsidewall and a second end portion opposite the first end portion andresting on the second sidewall; and

the first sidewall and the second sidewall have an interface areagreater than the adjustment amount.

4. The coke oven chamber of claim 3 wherein the monolith crown comprisesa plurality of adjacent arches.

5. The coke oven chamber of claim 1 wherein the monolith crown comprisesa non-arch shape.

6. The coke oven chamber of claim 1 wherein the monolith crown comprisesa generally flat shape.

7. The coke oven chamber of claim 1 wherein the monolith crown comprisesa thermally-volume-stable material.

8. The coke oven chamber of claim 1 wherein the monolith crown comprisesat least one of a fused silica, zirconia, or refractory material.

9. The coke oven chamber of claim 1 wherein the chamber comprises ahorizontal heat recovery coke oven chamber.

10. The coke oven chamber of claim 1 wherein the monolith crown meets atleast one of the first sidewall or the second sidewall with anoverlapping or interlocking joint.

11. The coke oven chamber of claim 1 wherein the first and secondsidewall are monolith sections.

12. The coke oven chamber of claim 1 wherein the sole flue section, thefirst and second sidewalls and the crown section are monolithcomponents.

13. The coke oven chamber of claim 1 wherein the oven includessubstantially no bricks.

14. A coke oven chamber, comprising:

a chamber floor;

a plurality of sidewalls generally orthogonal to the chamber floor; anda monolith component positioned above the chamber floor and at leastpartially spanning an area between at least two sidewalls, wherein themonolith component comprises a thermally-volume-stable material.

15. The coke oven chamber of claim 14 wherein thethermally-volume-stable material comprises fused silica or zirconia.

16. The coke oven chamber of claim 14 wherein the monolith componentcomprises a surface parallel, arched, or angled relative to the floor.

17. The coke oven chamber of claim 14 wherein the chamber comprises acoking chamber or a sole flue.

18. The coke oven chamber of claim 17 wherein the chamber comprises aplurality of monolith components.

19. A method of turning down a horizontal heat recovery coke oven, themethod comprising:

forming a coke oven structure having a floor, a first sidewall and asecond sidewall opposite the first sidewall, and an oven crown over thefloor in a space at least partially between the first sidewall and thesecond sidewall, wherein at least one of the floor, the first sidewall,the second sidewall, or the oven crown are monolithic components;heating the coke oven;turning down the coke oven below a thermally-volume-stable temperature;andmaintaining the coke oven structure.

20. The method of claim 19 wherein forming the coke oven structurecomprises forming an oven at least partially of thermally-volume-stablematerial.

21. The method of claim 19 wherein forming the coke oven structurecomprises forming a monolith spanning at least a portion of a distancebetween the first sidewall and the second sidewall.

22. The method of claim 19 wherein forming the coke oven structurecomprises forming a coke oven structure at least partially of silicabrick, and wherein turning down the coke oven below athermally-volume-stable temperature comprises turning down the coke ovenbelow a temperature of 1,200° F.

23. The method of claim 19 wherein turning down the coke oven comprisesturning down oven operation to 50% of operational capacity or less.

24. The method of claim 19 wherein turning down the coke oven comprisesturning off the oven.

25. A coke oven chamber, comprising:

an oven floor;

a forward end portion and a rearward end portion opposite the forwardend portion; a first sidewall extending vertically upward from the floorbetween the front wall and the back wall and a second sidewall oppositethe first sidewall;

a crown positioned above the floor and spanning from the first sidewallto the second sidewall; and

a sole flue comprising a thermally-volume-stable material and having aplurality of adjacent runs between the first sidewall and the secondsidewall.

26. The coke oven chamber of claim 25 wherein thethermally-volume-stable material comprises fused silica or zirconia.

27. The coke oven chamber of claim 25 wherein the sole flue includes atleast one sole flue wall comprised of a plurality of sole flue wallsegments.

28. The coke oven chamber of claim 27 wherein the sole flue wallsegments are comprised of a thermally-volume-stable material.

29. The coke oven chamber of claim 27 wherein the sole flue wallsegments are coupled with one another by cooperating ridge and groovefeatures associated with end portions of the sole flue wall segments.

30. The coke oven chamber of claim 27 wherein the sole flue wallsegments are coupled with one another by cooperating notch andprojection features associated with end portions of the sole flue wallsegments.

31. The coke oven chamber of claim 25 wherein the sole flue includes atleast one blocking wall section coupled with, and extending generallytransverse from, at least one sole flue wall; the at least one blockingwall section comprising of a thermally-volume-stable material.

32. The coke oven chamber of claim 31 wherein the at least one blockingwall section and at least one sole flue wall are coupled with oneanother by cooperating ridge and groove features associated with an endportion of the at least one blocking wall segment and a side portion ofthe at least one sole flue wall.

33. The coke oven chamber of claim 25 wherein the sole flue includes atleast one generally J-shaped arch section spanning a gap between an endportion of at least one sole flue wall and a sole flue end wall.

34. The coke oven chamber of claim 33 wherein the arch section includesan arched upper end portion and a leg depending from one end of theupper end portion; an opposite free end of the arched upper end portionoperatively coupled with the sole flue end wall between a sole fluefloor and the oven floor.

35. The coke oven chamber of claim 33 wherein the at least one archsection is comprised of a thermally-volume-stable material.

36. The coke oven chamber of claim 25 wherein the sole flue includes atleast one sole flue corner section having a rearward face that is shapedto engage a corner area of at least one of the plurality of adjacentruns and an opposing, curvilinear or concave forward face; the sole fluecorner section being positioned to direct fluid flow past the cornerarea.

37. The coke oven chamber of claim 36 wherein the at least one sole fluecorner section is comprised of a thermally-volume-stable material.

38. The coke oven chamber of claim 25 wherein the sole flue includes atleast one sole flue corner section having a rearward face that is shapedto engage a corner area of at least one of the plurality of adjacentruns and an opposing, curvilinear or concave forward face; the sole fluecorner section being positioned to direct fluid flow past the cornerarea.

39. The coke oven chamber of claim 25 wherein the oven chamber isfurther comprised of downcommer channels that extend through at leastone of the first sidewall and second sidewall; the downcommer channelsbeing in open fluid communication with the oven chamber and the soleflue.

40. The coke oven chamber of claim 39 wherein the downcommer channelshave curved sidewalls.

41. The coke oven chamber of claim 39 wherein the downcommer channelshave various geometric shapes cross-sections.

42. The coke oven chamber of claim 39 wherein the downcommer channelsare cast using a thermally-volume-stable material.

43. The coke oven chamber of claim 39 wherein the downcommer channelsare formed from a plurality of channel blocks having channels thatpenetrate the channel blocks; the plurality of channel blocks beingvertically stacked such that channels from adjacent channel blocks alignwith one another to define sections of downcommer channels.

44. The coke oven chamber of claim 43 wherein at least one channel blockincludes channels that penetrate upper and lower end portions of thechannel block and a side of the channel block to provide outlets for thedowncommer channels.

45. The coke oven chamber of claim 39 further comprising a downcommercover operatively coupled with an opening to at least one downcommerchannel; the downcommer cover including a plug that is shaped to bereceived within an access opening that penetrates the downcover cover.

46. The coke oven chamber of claim 25 wherein the oven chamber isfurther comprised of uptake channels that extend through at least one ofthe first sidewall and second sidewall; the uptake channels being inopen fluid communication with the sole flue and a fluid outlet of thecoke oven chamber.

47. The coke oven chamber of claim 46 wherein the uptake channels havevarious geometric shapes sidewalls.

48. The coke oven chamber of claim 46 wherein the uptake channels havevarious geometric shapes cross-sections.

49. The coke oven chamber of claim 46 wherein the uptake channels arecast using a thermally-volume-stable material.

50. The coke oven chamber of claim 46 wherein the uptake channels areformed from a plurality of channel blocks having channels that penetratethe channel blocks; the plurality of channel blocks being verticallystacked such that channels from adjacent channel blocks align with oneanother to define sections of uptake channels.

51. The coke oven chamber of claim 50 wherein at least one channel blockincludes channels that penetrate upper and lower end portions of thechannel block and a side of the channel block to provide inlets for theuptake channels.

From the foregoing it will be appreciated that, although specificembodiments of the technology have been described herein for purposes ofillustration, various modifications may be made without deviating fromthe spirit and scope of the technology. For example, while severalembodiments have been described in the context of HHR ovens, in furtherembodiments, the monolith or thermally-volume-stable designs can be usedin non-HHR ovens, such as byproduct ovens. Further, certain aspects ofthe new technology described in the context of particular embodimentsmay be combined or eliminated in other embodiments. For example, whilecertain embodiments have been discussed in the context of a crown for acoking chamber, the flat crown, monolith crown, thermally-volume-stablematerials, and other features discussed above can be used in otherportions of a coke oven system, such as a crown for a sole flue.Moreover, while advantages associated with certain embodiments of thetechnology have been described in the context of those embodiments,other embodiments may also exhibit such advantages, and not allembodiments need necessarily exhibit such advantages to fall within thescope of the technology. Accordingly, the disclosure and associatedtechnology can encompass other embodiments not expressly shown ordescribed herein. Thus, the disclosure is not limited except as by theappended claims.

We claim:
 1. A coke oven chamber, comprising: a monolith sole fluesection having a serpentine path, the monolith sole flue comprising; asole flue front wall extending vertically upward from a sole flue floorand a sole flue back wall opposite the sole flue front wall; a firstsole flue sidewall extending vertically upward from the sole flue floorbetween the sole flue front wall and the sole flue back wall and asecond sole flue sidewall opposite the first sole flue sidewall; amonolith sole flue crown positioned above the sole flue floor andspanning from the first sole flue sidewall to the second sole fluesidewall, such that first and second end portions of the monolith soleflue crown are supported by respective upper end portions of the firstand second sole flue sidewalls; the monolith sole flue crown having aflat upper surface that defines an oven chamber floor surface; and thesole flue front wall, sole flue back wall, first sole flue sidewall,second sole flue sidewall, sole flue floor, and monolith sole flue crowndefining a serpentine fluid pathway; a front wall extending verticallyupward from the monolith sole flue section and a back wall opposite thefront wall; a first sidewall extending vertically upward from the floorbetween the sole flue front wall and the sole flue back wall and asecond sidewall opposite the first sidewall; and a crown positionedabove the monolith sole flue section and spanning from the firstsidewall to the second sidewall.
 2. The coke oven chamber of claim 1wherein the monolith sole flue crown comprises a plurality of monolithportions spanning from the first sole flue sidewall to the second soleflue sidewall, wherein the plurality of monolith portions are positionedadjacent to one another between the sole flue front wall and the soleflue back wall.
 3. The coke oven chamber sole flue of claim 1 whereinthe monolith sole flue crown comprises a non-arch shape.
 4. The cokeoven chamber of claim 1 wherein the monolith sole flue crown comprises aflat shape.
 5. The coke oven chamber sole flue of claim 1 wherein themonolith sole flue crown comprises a thermally-volume-stable material.6. The coke oven chamber of claim 1 wherein the monolith sole flue crowncomprises at least one of a fused silica, zirconia, or refractorymaterial.
 7. The coke oven chamber of claim 1 wherein the coke ovencomprises a horizontal heat recovery coke oven chamber.
 8. The coke ovenchamber of claim 1 wherein the monolith sole flue crown meets at leastone of the first sole flue sidewall or the second sole flue sidewallwith an overlapping or interlocking joint.
 9. The coke oven chamber ofclaim 1 wherein the first sole flue sidewall and second sole fluesidewall are monolith sections extending between the sole flue floor andthe sole flue crown.
 10. The coke oven chamber of claim 1 wherein thefirst sole flue sidewall, second sole flue sidewalls and the sole fluecrown comprise monolith components.
 11. The coke oven chamber of claim 1wherein the oven includes substantially no bricks.
 12. A coke ovenchamber, comprising: a sole flue portion, comprising: a sole flue frontwall extending upward from a sole flue floor; a sole flue back wallopposite the sole flue front wall; a first sole flue sidewall extendingupward from the sole flue floor between the sole flue front wall and thesole flue back wall; a second sole flue sidewall extending upward fromthe sole flue floor and opposite the first sole flue sidewall; amonolith sole flue crown above the sole flue floor and having a flatupper surface that defines an oven chamber floor surface, wherein firstand second end portions of the monolith sole flue crown are supported byrespective upper end portions of the first and second sole fluesidewalls; and a front wall extending upward from the sole flue portion;a back wall opposite the front wall; a first sidewall extendingvertically upward and between the front wall and the back wall; a secondsidewall opposite the first sidewall; and a crown positioned above themonolith sole flue section and spanning from the first sidewall to thesecond sidewall.
 13. The coke oven chamber of claim 12, wherein themonolith sole flue crown and at least a portion of the first sole fluesidewall comprise a monolith structure.
 14. The coke oven chamber ofclaim 12, wherein the monolith sole flue crown, first sole fluesidewall, and second sole flue sidewall comprise a monolith structure.15. The coke oven chamber of claim 12, wherein the first end portion ofthe monolith sole flue crown abuts a topmost surface of the first soleflue sidewall.